Tackling the efficiency gap

with capacity building

Swiss Training Program Industrial
Energy Optimisation (IEO)

Rita Werle, Impact Energy Inc., Zurich Switzerland

13 Sept 2016 eceee, Berlin Rita Werle 1
eceee Industrial Summer Study, Berlin, 13 September 2016
Content
•  Introduction: why motors?
•  New training program:
Industrial Energy Optimisation (IEO)
–  Goal & target audience
–  Timeline
–  Organisation
–  Content
•  Lessons learned & way forward

13 Sept 2016 eceee, Berlin Rita Werle 2

 Introduction

13 Sept 2016 eceee, Berlin Rita Werle 3

Impact Energy
Rita Werle •  consulting
Managing Director
policy •  energy efficiency in
industry
Rolf Tieben
Technical Director
•  focus: electric motor
technology systems

Conrad U. Brunner
Senior Advisor

13 Sept 2016 eceee, Berlin Rita Werle 4

Industrial electricity consumption

12,2%

motors

lighting, IT & communication,

87,8% HVAC, cafeteria, ohmic
resistances

Number of examined firms: 25

Total electricity consumption: 691 GWh/a
Electricity consumption motors: 607 GWh/a

13 Sept 2016 eceee, Berlin Rita Werle 5

Topmotors program

•  Since 2007
•  Information &
awareness raising:
–  Motor Summit
–  Workshops
–  Fact sheets
–  Training
–  Pilot projects
–  Newsletter 11/12 Oct 2016 Zurich
www.topmotors.ch www.motorsummit.ch
13 Sept 2016 eceee, Berlin Rita Werle 6
 Why a training program for
motor systems?

•  Swiss CO2-law and its implementation: focus so far on thermal energy

•  Trainings focused on buildings & renewable energy
•  Only lately: also industrial thermal processes
•  Electric efficiency: neglected

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Practical experience

56% of motors are older than their operating life expectancy;

13 Sept 2016 eceee, Berlin Rita Werle 8
these older motors are 99% too old.
 Industrial Energy Optimisation
(IEO)
2013 – 2016
supported by the Swiss Federal Office of Energy

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Training
Goal Target group
•  Systematically analyze •  primary: technical staff in
motor systems
middle / large industrial
•  Identify efficiency projects
•  Implement multi-year factories
improvement plan •  work experience (min.
•  Convince upper technical apprenticeship)
management to invest
•  Dialogue with external •  secondary: energy
engineers, manufacturers, consultants, utilities,
service companies public authorities, etc.
•  Evaluate costs & savings,
life cycle costs

13 Sept 2016 eceee, Berlin Rita Werle 10

 Timeline
Expansion &
Pilot regular
Feasibility Build-up implementation imlementation
German part (also French
part)

2013 – 2014 2015 2016 from 2017

1.  16 potential
training sites
2.  Manufacturers
3.  Associations
4.  Utilities
5.  Cantons
6.  End users

Rita Werle 11
IEO Organisation
IEO supporting organisations
strategic guidance & marketing

IEO program management IEO advisory board

national coordination program content

German language French language

HSLU HEIG-VD
Horw Yverdon-les-Bains

13 Sept 2016 eceee, Berlin

www.hslu.ch/w103 www.entrainements-electriques.ch 12
Content
Topmotors IEO Gamma
1 2 3 4 5 6

Break

Break
FR SA FR SA FR SA

Registration

Technology 1: Efficiency

Technology 6: Measures
14: 20: Efficiency 27: Individual

Energy management 2
09:15-10:00 1: Introduction 7: Efficiency 31: Test
Communication potential measures

Technik 4: M-S-C
Introduction

Praxisarbeit (Teil 2): Analysiere Anlage und suche

10:15 - 28: Package of
2: Swiss Energy 8: Losses 15: Convincing 21: Motor list
11:00 measures 32a: Presentation

Practical assignment (1): search object

practical

Verbesserungsmöglichkeiten
29: assignments (1-6)
11:15 - 3: Minimum 16: Monitoring & 22: Decision
9: Motors Recommendati
12:00 requirements targetting Maker
ons
Lessons

Technology 5: Measuring
13:15 -
Technology 2: Systems
Energy management 1

4: Basics 10: Converter 17: Fans 23: Measuring

Technik 3: Systeme
14:00 32b: Presentation
practical
14:15 - 18: Cold 24: Standard assignments (7-12)
5: Profitability 11: Pumps (1) 30: Lab
15:00 compressors Test Protocol

15:15 - 6: Electricity 19: Air

12: Pumps (2) 25: System 33: Feedback
16:00 costs compressors

16:15 - 13: Practical 26:Practical

Q&A Q&A Q&A
17:00 assignment 1 assignment 2

End
Impact Energy, 20160324

•  6 days (2x3) during 6 weeks

•  Unique selling proposition: Energy management & technology (systems!)
•  1/3 training in class - 1/3 practical work - 1/3
13 Sept 2016 eceee, Berlin
work at home
Rita Werle 13
Motor-Systems-Check

Tools

SOTEA
Software tool for efficient motor
systems

ILI+ Intelligent list

STR Standard Test Report

MST Motor Systems Tool

Download: www.topmotors.ch
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German & French

www.hslu.ch/w103 www.entrainements-electriques.ch
13 Sept 2016 eceee, Berlin Rita Werle 15
Lessons learned
•  Combination with university professors
(theoretical) & technical practicioners:
challenging
•  Branding: renowned host universities &
Topmotors & Swiss Federal Office of
Energy
•  Practical work in lab: demonstrators
•  7 participants at HSLU: secondary target
group
•  Feedback:
–  good topic, structure, timing & duration
–  more practical work & examples!
–  start Motor-Systems-Check early
–  exchange among participants
–  access to pilot factories/machines:
no problem
–  more attention to SME-approach
–  less energy management, more focused

13 Sept 2016 eceee, Berlin Rita Werle 16

Way forward

•  First French course in spring 2017

•  Planning of next German course
•  Marketing!
•  Export to other countries? (Germany, Austria, France,
China, etc.)

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Thanks for your attention!
Questions?

Contact
•  Rita Werle, rita.werle@impact-energy.ch www.hslu.ch/w103
•  Conrad U. Brunner, cub@impact-energy.ch
•  Rolf Tieben, rolf.tieben@impact-energy.ch
•  www.topmotors.ch
•  www.motorsummit.ch
•  www.motorsystems.org
•  www.impact-energy.ch

13 Sept 2016 eceee, Berlin Rita Werle www.entrainements-electriques.ch

18
 Swiss motor policy

Minimum
International
Energy
exchange Performance
Standards

Market transformation
Information Financial
& education incentives

13 Sept 2016 eceee, Berlin Rita Werle 19

Decision Making

Board Room
(Manager: decision)

exchange
Training
Industrial
plant

Boiler Room
(Engineer: Service
implementation)
Manufacturers

13 Sept 2016 eceee, Berlin Rita Werle 20

Survey
Survey participants n=34 •  Analysis of existing
programs
educational
institute •  Telephone interviews
planning
engineer •  Questionnaire types:
9%
9%
manufacturer 1.  Educational institutes
industry
2.  Manufacturers
14% 50%
association 3.  Associations
utility
12% 4.  Utilities
canton 5.  Cantons
3% 3%
6.  End users
end user

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Feasibility study
2013/14

Survey 16 potential training sites

•  Analysis of existing programs
•  Telephone interviews
•  Targeted:
1.  Educational institutes
2.  Manufacturers
3.  Associations
4.  Utilities
5.  Cantons
6.  End users

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Choice of sites
•  Motivation to be a host
•  Central location, geographically well-positioned to reach a large number of potential program
participants
•  Easy transport access (availability by public transportation)
•  Available type and size of class rooms
•  Availability of a testing laboratory: size, measurement equipment, possibilities for testing motors,
pumps, fans, compressors, availability of lab trainers
•  Availability of teachers for the different topics of the training program (including accompanying the
individual practical assignments of training participants), their professional and didactic qualification and
experience
•  Reputation of the educational institution in the field of energy efficiency
•  Experience of the institution with building up and executing continued education programs
•  Courses already offered or planned with similar content as IEO
•  Target group and profile of participants of continued education programs already offered or planned by
the institution
•  Network for reaching potential participants (marketing)
•  Existing contacts to industrial producers (e.g. motor and machine manufacturers) and industrial users
•  Possibility for obtaining European Credit Transfer System (ECTS) points for a successful completion of
the training
•  In kind contributions for class rooms, laboratory, teachers and marketing activities.

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Company size
Electricity consumption in industry and service sectors (GWh/a)
10 000 200 000
Elektricity consumption by class of size (GWh/a)

9 000 8 686 Total 31'957 GWh/a 180 000

Total 356'817 factories
7 912
8 000 160 000
7 027

Number of factories per class of size

7 000 140 000

6 000 120 000

5 000 100 000

4 000 80 000
3 209 3 118
3 000 60 000

2 000 1 752 40 000

1 000 20 000
253
- -
< 10 MWh 10 - 100 MWh 100-500 MWh 0.5 - 3 GWh 3 - 10 GWh 10 - 20 GWh > 20 GWh

Classes of annual electricity consumption

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 Factory & personnel typology
Factory Electric Number Electric In-house staff Prior
size energy con- of energy for energy education of
sumption factories consump efficiency technical staff
in class -tion of projects
factories
in class
Small < 0.5 GWh/a 96.1% 38% usually no
Medium 0.5 to 10 3.7% 34% some, lacking apprenticeship
GWh/a competence &
capacity
Large > 10 GWh/a 0.2% 28% yes, lacking electrical /
specific mechanical
knowledge & degree
experience

Factories with more than 0.5 GWh/a electric energy consumption:

•  3.9% of total number
•  1362%
Sept 2016 eceee, Berlin
of total consumption Rita Werle 25
Motor system

Quelle: 4E EMSA, 2014

13 Sept 2016
Rita Werle
eceee, Berlin 26
Labor HEIG-VD: Pump demonstrator

Idea: demonstrator for

ventilators in Horw
(HSLU)

13 Sept 2016 eceee, Berlin Rita Werle 27